A. Kayode Coker - Chemical Process Engineering Volume 1

1 Cover

2 Title Page Chemical Process Engineering Design, Analysis, Simulation and Integration, and Problem Solving With Microsoft Excel – UniSim Design Software Computation, Physical Property, Fluid Flow, Equipment & Instrument Sizing, Pumps & Compressors, Mass Transfer A. Kayode Coker and Rahmat Sotudeh-Gharebagh

3 Copyright

4 Companion Web Page

5 Gratitude

6 Preface

7 Acknowledgments

8 About the Authors

9 1 Computations with Excel Spreadsheet-UniSim Design Simulation SECTION I - NUMERICAL ANALYSISINTRODUCTION SOLVER LINEAR REGRESSION MULTIPLE REGRESSION POLYNOMIAL REGRESSION SIMULTANEOUS LINEAR EQUATIONS NONLINEAR EQUATIONS INTERPOLATIONS INTEGRATIONS DIFFERENTIAL EQUATIONS EXAMPLES AND SOLUTIONS SECTION II – PROCESS SIMULATIONINTRODUCTION EXAMPLES AND SOLUTIONS References

10 2 Physical Property of Pure Components and Mixtures PURE COMPONENTS MIXTURES DIFFUSION COEFFICIENTS COMPRESSIBILITY Z-FACTOR SOLUBILITY AND ADSORPTION References

11 3 Fluid FlowINTRODUCTION EQUIVALENT LENGTH OF VARIOUS FITTINGS AND VALVES PRESSURE DROP CALCULATIONS FOR SINGLE-PHASE INCOMPRESSIBLE FLUIDS COMPRESSIBLE FLUID FLOW IN PIPES TWO-PHASE FLOW IN PROCESS PIPING VAPOR-LIQUID TWO-PHASE VERTICAL DOWNFLOW LINE SIZES FOR FLASHING STEAM CONDENSATE FLOW THROUGH PACKED BEDS EXAMPLES AND SOLUTIONS References

12 4 Equipment SizingINTRODUCTION SIZING OF VERTICAL AND HORIZONTAL SEPARATORS SIZING OF PARTLY FILLED VESSELS AND TANKS PRELIMINARY VESSEL DESIGN CYCLONE DESIGN GAS DRYER DESIGN EXAMPLES AND SOLUTIONS References

13 5 Instrument SizingINTRODUCTION CONTROL VALVE SIZING References

14 6 Pumps and Compressors SizingPUMPS Pump Design Standardization Basic Parts of a Centrifugal Pump Impellers Casing Shaft CENTRIFUGAL PUMP SELECTION Single-Stage (Single Impeller) Pumps Hydraulic Characteristics for Centrifugal Pumps Friction Losses Due to Flow Velocity Head Friction NET POSITIVE SUCTION HEAD (NPSH) AND PUMP SUCTION General Suction System Reductions in NPSHR Charting NPSHR Values of Pumps Net Positive Suction Head (NPSH) Specific Speed Rotative Speed Pumping Systems and Performance POWER REQUIREMENTS FOR PUMPING THROUGH PROCESS LINES Hydraulic Power AFFINITY LAWS CENTRIFUGAL PUMP EFFICIENCY Centrifugal Pump Specifications Pump Specifications (Figures 6.43a and b) Steps in Pump Sizing Reciprocating Pumps Significant Features in Reciprocating Pump Arrangements Application Performance Discharge Flow Patterns HORSEPOWER Pump Selection Selection Rules-of-Thumb A CASE STUDY Variables Descriptions SIMULATION ALGORITHM Problem Discussion Pump Cavitation Factors in Pump Selection COMPRESSORS General Application Guide Specification Guides GENERAL CONSIDERATIONS FOR ANY TYPE OF COMPRESSOR FLOW CONDITIONS Fluid Properties Compressibility Corrosive Nature Moisture Special Conditions Specification Sheet PERFORMANCE CONSIDERATIONS Heat Rejected to Water Drivers Ideal Pressure – Volume Relationship Actual Compressor Diagram DEVIATIONS FROM IDEAL GAS LAWS: COMPRESSIBILITY Adiabatic Calculations Charles’ Law at Constant Pressure [9] Amonton’s Law at Constant Volume [9] Combined Boyle’s and Charles’ Laws Entropy Balance Method [7] Isentropic Exponent Method [7] COMPRESSION RATIO Horsepower Single Stage Actual Brake Horsepower, Bhp Actual Brake Horsepower, Bhp (Alternate Correction for Compressibility) Temperature Rise – Adiabatic Temperature Rise – Polytropic A CASE STUDY USING UNISIM DESIGN R460.1 SOFTWARE FOR A TWO–STAGE COMPRESSION Solution Accidentally Closing the PFD Object Palette Specifications COMPRESSION PROCESS ADIABATIC HEAD DEVELOPED PER SINGLE-STAGE WHEEL Polytropic Head Polytropic Brake Horsepower Speed of Rotation TEMPERATURE RISE DURING COMPRESSION Sonic or Acoustic Velocity MACH NUMBER [35] Specific Speed COMPRESSOR EQUATIONS IN SI UNITS Polytropic Compressor Adiabatic Compressor Efficiency Mass Flow Rate, w Mechanical Losses Estimating Compressor Horsepower Multistage Compressors Multicomponent Gas Streams AFFINITY LAWS Speed Impeller Diameters (Similar) Impeller Diameter (Changed) Effect of Temperature AFFINITY LAW PERFORMANCE TROUBLESHOOTING OF CENTRIFUGAL AND RECIPROCATING COMPRESSORS NOMENCLATURE Greek Symbols Subscripts Nomenclature Subscripts Greek Symbols ReferencesPumps Bibliography References Bibliography

15 7 Mass TransferINTRODUCTION VAPOR LIQUID EQUILIBRIUM BUBBLE POINT CALCULATION DEW POINT CALCULATION EQUILIBRIUM FLASH COMPOSITION Nomenclature TOWER SIZING FOR VALVE TRAYS PACKED TOWER DESIGN DETERMINATION OF PLATES IN FRACTIONATING COLUMNS BY THE SMOKER EQUATIONS MULTICOMPONENT DISTRIBUTION AND MINIMUM TRAYS IN DISTILLATION COLUMNS EXAMPLES AND SOLUTIONS References

16 Index

17 Also of Interest

18 End User License Agreement

1 Chapter 1 Table 1.1 Selected basic functions of Excel spreadsheet [2, 5]. Table 1.2 Selected applied functions of Excel spreadsheet for design and simulat... Table 1.3 Syntax for finding trendline coefficients [7]. Table 1.4 Input data for liquid mixing experiment. Table 1.5 Input data for fluid flow experiments. Table 1.6 xy data for polynomial approximation. Table 1.7 Blend specifications. Table 1.8 Design and reaction data for continuous stirred tanks. Table 1.9 Flow gas data at various temperatures. Table 1.10 Kinetic and concentration data for the batch reactor. Table 1.11 Benefits of using process simulators for engineers and scientists. Table 1.12 List of mostly used chemical process simulators. Table 1.13 Good simulation practice.

2 Chapter 2Table 2.1 The temperature range for the surface tension.Table 2.2 Calculation of specific gravity of natural gas.

3 Chapter 3Table 3.1 Values of K1 and K∞ for the two-K method for pipe fittings. Source: H...Table 3.2 Excess head loss “K” correlation due to changes in pipe size [1].Table 3.3 Equivalent roughness of various surfaces (Source [6]).Table 3.4 Recommended fluid velocity and maximum ΔP for carbon steel vapor lines...Table 3.5 Approximate k values for some common gases (68°F, 14.7 psia).Table 3.6 Friction factors for total turbulence in new commercial steel pipes.Table 3.7 Characteristic linear Velocities of two-phase flow regimes.Table 3.8 Characteristic linear velocities of two-phase flow regimes [26].

4 Chapter 4Table 4.1 Design criteria for Reflux Distillate Accumulators.Table 4.2 Operator factors for external units.Table 4.3 Head blank diameter factor (H.Fac).Table 4.4 Effect of variables on Cyclone Performance.Table 4.5 Cyclone operational and design data.Table 4.6 Dryer operational data.

5 Chapter 5Table 5.1 Flow coefficients for control valves.Table 5.2 Correction factors for control valve flow coefficient.Table 5.3 Cv table for quick opening trim.Table 5.4 Cv table for linear trim.

6 Chapter 6Table 6.1 General types or classification of pumps.Table 6.2 Approximate capacity-head ranges for centrifugal pumps.Table 6.3 Effects of fluid density on head.Table 6.4 Basic parts of a centrifugal pump.Table 6.5 Pump selection guide.Table 6.6 Troubleshooting centrifugal pumps.Table 6.7 Pump installation check list [30].Table 6.8 General compression and vacuum limits.Table 6.9 Comparison of performance for propane.Table 6.10 Compressibility Factors, Z.Table 6.11 Approximate ratio of specific heats (“k” values) for various gases.Table 6.11a Constants for molal heat capacity.Table 6.12 Properties of the gas mixture.Table 6.13 Polytropic efficiencies for various types of machines.Table 6.14 Approximate mechanical losses as a percentage of a gas power requirem...Table 6.15 Properties of the gas mixture.Table 6.16 Probable causes of reciprocating compressor trouble.Table 6.17 Probable causes of centrifugal compressor trouble.

7 Chapter 7Table 7.1 Ways to produce two-phase mixture [1].Table 7.2 Equilibrium flash criteria.Table 7.3 Values of G and H for each tray spacing.Table 7.4 Recommended values for foam factor and residence time.Table 7.5 Tower diameter versus cross sectional areas.Table 7.6 Downcomer dimensions.Table 7.7 Downcomer dimensions.Table 7.8 Downcomer dimensions.Table 7.9 Tower diameter versus cross sectional areas.Table 7.10 Determining number of passes.Table 7.11 Pressure-drop correlations for packed towers. Source: van Winkle [17]...Table 7.12 Generalized pressure drop rules. Source: Branan [25].Table 7.13 Packing factors (Source: Eckert [26]).Table 7.14 Constants for each pressure drop correlation. Source: Blackwell [13].Table 7.15 Composition of feed.Table 7.16 Feed composition to a natural gas liquefaction plant.Table 7.17 Bubble and dew point temperatures.Table 7.18 Constants for each pressure drop correlation.